Gauge Plate

ABSTRACT

A gauge plate insulator includes a body having a first side and a second side positioned opposite the second, with the first side of the body defining a planar surface, and the body defining a first opening and a second opening, and a leg extending from the second side of the body and configured to be positioned between first and second gauge plate members. The leg is positioned between the first and second openings of the body, with the body and leg formed integrally from a fiber-reinforced polymer.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to United States ProvisionalApplication Ser. No. 62/501,327, filed May 4, 2017, which is herebyincorporated by reference in its entirety.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to an insulating joint for use in a railsystem to electrically isolate parts of the rail system from each other.

Description of Related Art

A rail system is generally divided into sections or blocks to be able todetect trains which permits more trains to travel on one stretch oftrack or rail. Each section is electrically isolated from all othersections so that when no train is present in the section, a highelectrical resistance can be measured over the parallel railbars in thesection. When a train enters a section, the train short circuitsadjacent railbars and the electrical resistance drops.

Railbars are generally welded to each other or attached to each other bya steel joint. High performance non-metallic joints are used forelectrically isolating two railbars in order to build an electricallyisolated section. Switches are insulated in the same way by dividingboth the gauge plate and switch rods into two parts and by joining therespective parts with a non-metallic or insulating joint.

Known non-metallic joints are very expensive because of the special highperformance material which has to endure high tensile and flexuralforces. In addition, a separate insulating plug must be utilized betweenends of the gauge plate or switch rod to prevent material buildup ofdebris which would then cause an electrical short.

U.S. Pat. No. 6,170,756 discloses a prior art gauge plate and switch rodinsulator. FIGS. 1-8 of U.S. Pat. No. 6,170,756 are reproduced as FIGS.1-8 of the present application. FIG. 1 shows a conventional gauge plateused to connect a first part or first member 10 and a second part orsecond member 12 of a switch rod. The switch rod is attached by brackets14 to the movable laterally spaced apart railbars of a switch which areused to maintain the gauge between movable railbars.

Two parts 10 and 12 are connected to each other by two T-shapedinsulating joints or switch plates 16 having T-shaped cross sections.Each insulating joint 16 includes a metallic core encased with anelectrically insulating material. Each core is T-shaped with a flat body17 a having a leg or ridge 17 b depending therefrom. Likewise, theinsulating joint 16 includes a flat body 17 c and a depending leg 17 d.The depending leg 17 d is received within a gap G defined between thefirst part 10 and the second part 12. Ends of the depending legs 17 dabut against each other. Alternatively, it is believed that the metalliccore can be a flat plate encased with an electrically insulatingmaterial replacing the depending leg or ridge 17 b completely withinsulating material as shown in FIG. 8. Alternatively, the insulatingjoints can be flat as opposed to T-shaped and an electric insulativefilling can be provided between the insulating joints in the gap Gdefined by the opposed ends of the first part 10 and the second part 12for electrically insulating these two parts 10 and 12 from each other.The insulating joints 16 are secured to the first part 10 and the secondpart 12 by a fastening arrangement of bolts 20, nuts 22, and washers 24.

More specifically, the insulating joint 16 includes a steel core 26 witha plurality of holes defined therein through which bolts 20 extend, aninsulating layer 28 encasing the steel core 26, and a plurality ofbushings 30 provided in the holes. FIG. 2 shows the bushings 30, whichare electrically insulated from the steel core 26. Either the bushings30 can have a separate bonded insulating layer or the insulating layercan be provided by the insulating layer 28.

The steel core 26, not the insulating layer 28, withstands tensileforces applied to the insulating joint 16 through parts 10 and 12. Thebushings 30 protect the steel core 26 and the insulating layer 28 fromwear caused by the bolts 20. As is evident, the installed T-shapedinsulating joint 16 sandwiches ends E and E′ of the two parts 10 and 12and are secured thereto.

FIGS. 3, 6, and 7 show a second embodiment of an insulating joint orgauge plate 40 for insulating a first part or first member 42 and asecond part or second member 44 for maintaining the gauge of two rails46 of a switch. The first part 42 and the second part 44 extend fromrespective laterally spaced apart rails 46.

The insulating joint or gauge plate 40 is T-shaped, i.e., has a T-shapedcross section, such that a part of the insulating joint 40 prevents theends of the first part 42 and the second part 44 from making electricalcontact. The insulating joint 40 includes a steel T-shaped core 48, afirst electrically insulating layer 50, which encases the core 48, andsteel bushings 52. As shown in FIG. 4, outer surfaces of each of thesteel bushings 52 are covered with a second electrically insulatinglayer 54. The T-shaped core 48 of the insulating joint 40, likewise,includes a flat body 47 a and a depending leg 47 b. The insulating joint40 includes a flat body 47 c and a depending leg 47 d. The depending leg47 d is received within a gap G′ between the first part 42 and thesecond part 44. Bolts 56, nuts 58, and washers 59 secure the insulatingjoint 40 to the first part 42 and the second part 44.

FIG. 8 shows another embodiment of an insulating joint 40′ that issimilar to the insulating joint 40 shown in FIGS. 3, 6, and 7. The onlydifference between insulating joint 40′ and insulating joint 40 is thatthe core 48 of insulating joint 40 is replaced with a flat plate core48′ of the insulating joint 40′ and the “T” is formed totally by thefirst electrically insulating layer 50.

FIG. 5 shows an insulating joint 60 similar to the insulating joint 16described above and can be used in a switch rod in lieu of insulatingjoints 16. The insulating joint 60 includes a T-shaped steel core 62, afirst insulating layer 64, and the steel bushings 52 having a secondelectrically insulating layer 54 shown in FIG. 4. The insulating joint60 is T-shaped such that, by mounting two insulating joints 60 on aswitch rod, the insulating joints 60 abut and entirely fill the spacebetween the two ends of the switch rod parts. Holes 66 are provided forreceipt of the steel bushings 52, which are used to receive fasteners.The bushings 52 and 30 define holes H that align with respective holesH′ defined in the first parts 10 and 42 and second parts 12 and 44 forreceipt of the bolts 20 and 56, respectively, and the bolts 20 and 56are electrically insulated from the respective metallic cores 26, 48,and 62.

All of the insulating joints are made by placing or providing the steelcore in a mold and molding around the steel core electrically insulatingmaterial, such as polyurethane, rubber, or other polymeric material,thereby forming a T-shaped electrically insulating plate. The metalliccore can be flat or T-shaped. The bushings at that time can be cast inplace. After the polyurethane hardens, the insulating rail joint isremoved from the mold and if the bushings for receipt of fasteners, suchas bolts 20 and 56, are not cast in place during molding, they can thenbe received by the insulating joint holes.

SUMMARY OF THE INVENTION

In one aspect, a gauge plate insulator includes a body having a firstside and a second side positioned opposite the second, with the firstside of the body defining a planar surface, and the body defining afirst opening and a second opening, and a leg extending from the secondside of the body and configured to be positioned between first andsecond gauge plate members. The leg is positioned between the first andsecond openings of the body, with the body and leg formed integrallyfrom a fiber-reinforced polymer.

The fiber-reinforced polymer may include at least one offiberglass-reinforced polyester, fiberglass-reinforced vinyl ester,fiberglass-reinforced polyurethane, and fiberglass-reinforced epoxy. Thefiber-reinforced polymer may include at least one of E-class fiberglassand S-class fiberglass.

The gauge plate insulator may further include a first fastenerconfigured to be received by the first opening and to secure the body toa first gauge plate member and a second fastener configured to bereceived by the second opening and to secure the body to a second gaugeplate member. The first and second fasteners may each be a buck collarand huck pin. The gauge plate insulator may further include a firstwasher configured to be positioned between a portion of the firstfastener and the body and a second washer configured to be positionedbetween a portion of the second fastener and the body. The first andsecond washers may each be a hardened flat washer.

The gauge plate insulator may further include a metallic plate, firstand second insulating washers, and first and second insulating bushings,with the metallic plate configured to be received by the first side ofthe body and defining first and second openings corresponding to thefirst and second openings of the body. The first insulating washer isconfigured to be positioned between a portion of the first fastener andthe metallic plate, with the second insulating washer configured to bepositioned between a portion of the second fastener and the metallicplate. The first insulated bushing may be received within the firstopening and configured to receive the first fastener and the secondinsulated bushing may be received within the second opening andconfigured to receive the second fastener.

The first opening may include a pair of spaced-apart openings and thesecond opening may include a pair of spaced-apart openings, with thegauge plate insulator further including a first elongate metallic plateextending between the pair of spaced-apart openings of the firstopening, and a second elongate metallic plate extending between the pairof spaced-apart openings of the second opening. The first and secondelongate metallic plates may be positioned parallel to the leg. Thegauge plate insulator may further include an insulating plate positionedin the first side of the body. The insulating plate may be formed fromglass fabric impregnated with epoxy resin.

In a further aspect, a method of manufacturing a gauge plate insulatorincluding a body having a first side and a second side positionedopposite the second, and a leg extending from the second side of thebody and configured to be positioned between first and second gaugeplate members, includes: impregnating a fiber reinforcement with resin;pulling the fiber reinforcement impregnated with the resin through aforming die to form a profile of the body and leg of the gauge plateinsulator; heating the profile to cure the resin; and cutting theprofile to a predetermined length.

In a further aspect, a gauge plate insulator includes a pair oflaterally spaced, elongated, planar metallic cores, with each of thelaterally spaced, elongated, planar metallic cores extending in a firstdirection, and an electrically insulating material encasing the pair oflaterally spaced, elongated, planar metallic cores, with theelectrically insulating material defining an insulating member thatincludes a T-shaped cross section defined by a body of the electricallyinsulating material and a leg of the electrically insulating materialthat depends from the body. The depending leg having an elongateddimension that extends in a second direction laterally to the firstdirection.

Each elongated, planar metallic core may have a first end and a secondend with the elongated dimension of the depending leg extending betweenthe first and second ends of each elongated, planar metallic core. Thegauge plate insulator may include a plurality of fastener holes, witheach fastener hole extending through the body of the electricallyinsulating member and one of the metallic cores. Each metallic core mayinclude two of the plurality of fastener holes, where one of the twofastener holes of the metallic core is positioned between the elongateddimension of the depending leg and the first end of the metallic core,and the other of the two fastener holes of the metallic core ispositioned between the elongated dimension of the depending leg and thesecond end of the metallic core.

The gauge plate insulator may further include an insulating bushing ineach fastener hole. The body of the electrically insulating material maydefine a pair of plateaus that extend above a surface of the body thatfaces away from the depending leg, where each plateau encases a surfaceof one of the metallic cores that faces away from the depending leg andat least a part of a side of the metallic core. A top of theelectrically insulating member may form an H-shape.

In a further aspect, a gauge plate insulator includes an L-shapedinsulating member having a base configured to be positioned betweenfirst and second gauge plate members and a leg extending from the base,a metallic backing plate having a first part configured to engage afirst gauge plate member, a second part configured to engage the leg ofthe L-shaped insulating member, and a third part extending between thefirst part and the second part of the metallic backing plate andconfigured to engage a portion of the base of the L-shaped insulatingmember, a first fastener configured to be received by a first openingdefined by the first part of the metallic backing plate to secure themetallic backing plate to a first gauge plate member and a secondfastener configured to be received by a second opening defined by thesecond part of the metallic backing plate and an opening defined by theleg of the L-shaped insulating member, and an insulation plateconfigured to be positioned between a portion of the second fastener andthe second part of the metallic backing plate.

In a further aspect, a gauge plate assembly includes a first gauge platemember having a thick section and a thin section adjacent an end of thefirst gauge plate member, a second gauge plate member having a thicksection and a thin section adjacent an end of the second gauge platemember, with a portion of the thin section of the first gauge platemember overlapping a portion of the thin section of the second gaugeplate member, an insulating member positioned between the first andsecond gauge plate members, at least one fastener extending through anopening extending through the thin sections of the first and secondgauge plate members and the insulating member, and an insulation platepositioned between a portion of the at least one fastener and the thinsection of the second gauge plate member.

The insulating member may be thicker adjacent to a transition betweenthe thick section and the thin section of the first gauge plate member,and the insulating member may be thicker adjacent to a transitionbetween the thick section and the thin section of the second gauge platemember. The insulation plate may be formed integrally with theinsulating member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of a first example prior art switch rodjoint;

FIG. 2 is a sectional view of a bushing shown in FIG. 1;

FIG. 3 is a sectional view of a second example prior art gauge platejoint;

FIG. 4 is a sectional view of a bushing shown in FIG. 3;

FIG. 5 is an exploded view, partially in section, of a third exampleprior art switch rod insulator plate;

FIG. 6 is a bottom plan view of the prior art gauge plate shown in FIG.3;

FIG. 7 is an elevational view of the prior art gauge plate shown in FIG.6;

FIG. 8 is an elevational view of an example prior art gauge platesimilar to that shown in FIG. 7 with a modified steel core;

FIG. 9A is a top view of a gauge plate in accordance with one embodimentof the present application;

FIG. 9B is a front view of the gauge plate of FIG. 9A;

FIG. 9C is a side view of the gauge plate of FIG. 9A;

FIG. 10A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 10B is an elevational view of the gauge plate of FIG. 10A;

FIG. 11A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 11B is an elevational view of the gauge plate of FIG. 11A;

FIG. 12A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 12B is an elevational view of the gauge plate of FIG. 12A;

FIG. 13A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 13B is an elevational view of the gauge plate of FIG. 13A;

FIG. 14A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 14B is an elevational view of the gauge plate of FIG. 14A;

FIG. 15A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 15B is an elevational view of the gauge plate of FIG. 15A;

FIG. 16A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 16B is an elevational view of the gauge plate of FIG. 16A;

FIG. 17A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 17B is an elevational view of the gauge plate of FIG. 17A;

FIG. 18A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 18B is an elevational view of the gauge plate of FIG. 18A;

FIG. 18C is a partial elevational view of the gauge plate of FIG. 18Aaccording to a further embodiment of the present application;

FIG. 18D is a partial elevational view of the gauge plate of FIG. 18Aaccording to a further embodiment of the present application;

FIG. 19A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 19B is an elevational view of the gauge plate of FIG. 19A;

FIG. 20A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 20B is an elevational view of the gauge plate of FIG. 20A;

FIG. 21A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 21B is an elevational view of the gauge plate of FIG. 21A;

FIG. 22A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 22B is an elevational view of the gauge plate of FIG. 22A;

FIG. 23A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 23B is an elevational view of the gauge plate of FIG. 23A;

FIG. 24A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 24B is an elevational view of the gauge plate of FIG. 24A;

FIG. 25A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 25B is an elevational view of the gauge plate of FIG. 25A;

FIG. 26A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 26B is an elevational view of the gauge plate of FIG. 26A;

FIG. 27A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 27B is a front view of the gauge plate of FIG. 27A;

FIG. 27C is a side view of the gauge plate of FIG. 27A;

FIG. 28A is a top view of a gauge plate in accordance with a furtherembodiment of the present application;

FIG. 28B is a front view of the gauge plate of FIG. 28A;

FIG. 28C is a side view of the gauge plate of FIG. 28A; and

FIG. 29 is a schematic view of a method of manufacturing a gauge plateinsulator according to one embodiment of the present application.

DESCRIPTION OF THE INVENTION

For purposes of the description hereinafter, the terms “end,” “upper,”“lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,”“lateral,” “longitudinal,” and derivatives thereof shall relate to theexample(s) as oriented in the drawing figures. However, it is to beunderstood that the example(s) may assume various alternative variationsand step sequences, except where expressly specified to the contrary. Itis also to be understood that the specific example(s) illustrated in theattached drawings, and described in the following specification, aresimply exemplary embodiments or aspects of the invention. Hence,specific dimensions and other physical characteristics related to theembodiments or aspects disclosed herein are not to be considered aslimiting.

With reference to FIGS. 9A-9C, a gauge plate insulator 70 according toone embodiment includes a pair of laterally spaced elongated planarmetallic cores 100. Longitudinal axes 102 of the metallic cores 100extend in a first direction shown by two-headed arrow 104. In anexample, the metallic cores 100 can be made of steel, although othersuitable materials may be utilized. Each metallic core 100 includes afirst end 114 and a second end 116. An electrically insulating material106 encases the pair of metallic cores 100. The electrically insulatingmaterial 106 defines a T-shaped electrically insulating member thatincludes a T-shaped cross section 108 defined by a body 110 of theelectrically insulating material 106 and a depending leg 112 of theelectrically insulating material that depends from said body 110.

The depending leg 112 has an elongated dimension that extends in asecond direction 118 laterally to the first direction 104. In anexample, the elongated dimension of the depending leg 112 extendsintermediate the first and second ends 114, 116 of each metallic core100.

The gauge plate insulator 70 includes a plurality of fastener holes 120.Each fastener hole 120 extends through the body 110 of the T-shapedelectrically insulating member and one of the metallic cores 100.

In an example, each metallic core 100 is comprised of two fastener holes120. One of said two fastener holes 120 of the metallic core 100 ispositioned between the elongated dimension 118 of the depending leg 112and the first end 114 of the metallic core 100. The other of said twofastener holes 120 of the metallic core 100 is positioned between theelongated dimension 118 of the depending leg 112 and the second end 116of the metallic core 100. An electrically insulating bushing 122 can beincluded in each fastener hole 120 to electrically insulate metalliccores 100 from the shaft of fasteners (not shown) inserted in saidbushings 122.

In an example, the electrically insulating material 106 can bepolyurethane, although other suitable materials may be utilized.

Optionally, each metallic core 100 can include an expansion slot 124that extends between the fastener holes 120 at the first and second ends114, 116 of said metallic core 100. The optional expansion slot 124 ofeach metallic core 100 can enable said metallic core 100 to withstandvibration and/or changes in temperature without deformation.

The body 110 of the electrically insulating material 106 can define apair of optional plateaus 126 that extend above the surface 127 of thebody 110 that faces away from the depending leg 112. As can be seen,each plateau 126 encases a surface of one of the metallic cores 100 thatfaces away from the depending leg 112 and at least part of a side 128 ofsaid metallic core 100. The pair of plateaus 126 are laterally spacedfrom each other in the second direction 118 and have longitudinal axesthat extend in the first direction shown by two-headed arrow 104.

The gauge plate insulator 70 shown in FIGS. 9A-9C can be used inreplacement of the gauge plate insulator 40 shown in FIG. 3.

With reference to FIGS. 10A-10B, a gauge plate insulator assembly 80according to a further embodiment includes an L-shaped insulator 134separating metallic plates 130 and 132 which correspond to first andsecond members 42 and 44 shown in FIG. 3. L-shaped insulator 134includes a leg 136 that rests atop of at least a part of the upperfacing surface of gauge plate 130 and a base 138 that depends downwardlyseparating the facing ends of plates 130 and 132. A metallic backingplate 140 has a first part 142 that rests on an upward facing surface ofplate 132, a second part 144 that rests on an upward facing surface ofthe leg 136 of insulator 134, and a third part 146 that transitionsvertically between first part 142 and second part 144 along at least apart of base 138 of insulator 134.

The gauge plate insulator assembly 80 can include a number of fastenerholes 148 that extend through gauge plate member 132 and first part 142of backing plate 140. Each fastener hole 148 can receive the shaft of aHuck pin 150 which can be secured in place via a flat washer 152 and aHuck collar 154 in a manner known in the art.

An insulating plate 156 can be positioned on a surface of second part144 of backing plate 140 that faces away from plate 130. The gauge plateinsulator assembly 80 can also include a number of fastener holes 158that extend through plate 130, leg 136 of insulator 134, second part 144of backing plate 140, and insulating plate 156. Each fastener hole 158can receive the shaft of a Huck pin 150 and can be secured in place viaa flat washer 152 and a Huck collar 154.

The gauge plate insulator assembly 80 shown in FIGS. 10A-10B can includea lifting bail 160 that includes parts 162 on either end that can besandwiched between flat washers 152 and first part 142 of backing plate140. The fastener holes 158 may include insulated bushings 164 in orderto electrically isolate plates 130 and 132 from each other.

The gauge plate insulator assembly 80 shown in FIGS. 10A-10B can be usedin replacement of the gauge plate 40 shown in FIG. 3.

With reference to FIGS. 11A-11B, a gauge plate assembly 80A according toa further embodiment includes metallic plates 166 and 168 having aninsulator 170 sandwiched therebetween. In this example, plates 166 and168 can replace first and second members 42 and 44 shown in FIG. 3.Plate 166 includes a thick section 172 and a thin section 174 adjacentan end 176 of plate 166. Similarly, plate 168 includes a thick section178 and a thin section 180 adjacent an end 182 of plate 168. Theboundary between thick section 172 and thin section 174 of plate 166 isdefined by a step 184 while the boundary between thick section 178 andthin section 180 of plate 168 is defined by a step 186. Plates 166 and168 are oriented such that steps 184 and 186 face in opposite directionwith the thin section 174 positioned above thin section 180 with asheet-like portion of insulator 170 disposed therebetween. A portion ofthe thin section 174 of the plate member 166 overlaps with a portion ofthe thin section 180 of the plate member 168.

Between thin sections 174 and 180 positioned as shown in FIG. 11B,insulator 170 can be a flat sheet having a thickness of, e.g., ⅛ inch.However, adjacent to step 186, insulator 170 can include a thickerportion that fills the gap between end 176 and the vertical wall of step186. Similarly, adjacent to step 184, insulator 170 can include athicker portion that fills the gap between end 182 and the verticalsurface of step 184. In an example, each thicker portion of insulator170 can have a thickness of, e.g., 7/16 inch.

An insulating plate or washer 188 can be positioned on a surface of thinsection 174 facing away from insulator 170. This example gauge plate caninclude a pair of fastener holes 190 each of which extends through thinsections 174 and 180, the plate-like portion of insulator 170therebetween, and through insulating plate 188 for receiving the shaftof a Huck pin 150 which can be secured in place via a flat washer 152and a Huck collar 154. The gauge plate assembly 80A can optionallyinclude a lifting bale 160 that includes parts 162 that can be receivedbetween washers 152 and insulating plate 188. Each fastener hole 190 canreceive an insulating bushing 192 to electrically insulate plates 166and 168 from each other.

With reference to FIGS. 12A-12B, a gauge plate assembly 80B according toa further embodiment is similar in most respects to the gauge plateassembly 80A shown in FIGS. 11A and 11B with at least the followingexceptions. The distances between steps 184 and 186 and ends 176 and182, respectively, are shorter and consequently the sheet-like portionof insulator 170 between thin sections 174 and 180 can have less area.Because the distance between shoulder 184 and end 176 of thin section174 is shorter, an edge of insulating plate or washer 188 can bepositioned in alignment with end 176 of thin section 174.

With reference to FIGS. 13A and 13B, a gauge plate assembly 80Caccording to a further embodiment is similar in most respects to thegauge plate 80B shown in FIGS. 12A-12B with at least the followingexceptions. The insulating plate 188 shown in FIGS. 12A-12B can bereplaced with a redesigned insulator 170 that includes a portion 194that extends upward from step 186 away from thin section 180 and thenextends in a direction (rightward in FIG. 12B) toward thick section 172of plate 166.

In this example, each fastener hole 190 also extends through the portion194 of insulator 170 that replaces insulating plate 188 in the exampleshown in FIGS. 12A-12B. Optionally, the height of insulating bushing 192can be extended through the part of fastener hole 190 that extendsthrough the portion 194 of insulator 170 shown in FIGS. 13A-13B.

With reference to FIGS. 14A and 14B, a gauge plate assembly 80Daccording to a further embodiment is similar in most respects to thegauge plate assembly 80B shown in FIGS. 12A and 12B with at least thefollowing exceptions. The distances between the vertical faces ofshoulders 184 and 186 and the ends 182 and 176, respectively, of thinsections 180 and 174 can be reduced to ⅜ inch, as compared to ¾ inchshown in the gauge plate assembly 80B of FIGS. 12A-12B.

With reference to FIGS. 15A and 15B, a gauge plate assembly 80Eaccording to a further embodiment is similar in most respects to thegauge plate assembly 80C shown in FIGS. 13A and 13B with at least thefollowing exceptions. The thickness of portion 194 of insulator 170 is ⅛inch as compared to ¾ inch in the gauge plate assembly 80C shown inFIGS. 13A and 13B. Also, the distances between the vertical walls ofsteps 184 and 186 and the ends 182 and 176, respectively, of thinsections 180 and 174 can be reduced to ⅜ inch versus ¾ inch in the gaugeplate assembly 80C shown in FIGS. 13A-13B.

With reference to FIGS. 16a and 16B, a gauge plate assembly 80Faccording to a further embodiment is similar in most respects to thegauge plate assembly 80B shown in FIGS. 12A and 12B with at least thefollowing exceptions. The height of insulator 170 between step 186 andend 176 is increased, e.g., by ⅛ inch, whereupon the upper facingsurface of this section of insulator 170 is flush with the top ofinsulating plate or washer 188.

With reference to FIGS. 17A and 17B, a gauge plate assembly 80Gaccording to a further embodiment is similar in most respects to thegauge plate assembly 80B shown in FIGS. 12A and 12B with at least thefollowing exceptions. The sum of the thickness of thin sections 174 and180 of plates 166 and 168, respectively, total the thickness of eachthick section 172 and 174 of these plates. In this example, thethickness of the plate-like area of insulator 170 between thin sections174 and 180 is 1/16 inch thick versus ⅛ inch thick in the example shownin FIGS. 12A and 12B. In addition, in order to account for thedifference in height between end 176 and the vertical wall of step 186when the sheet-like portion of insulation is disposed between thinsections 174, 180, the section of insulator between end 176 and thevertical wall of step 186 is tapered so as to cover both verticalsurfaces of end 176 and step 186 without having part of insulator 170extend above or below either surface. Similar comments apply in respectof the section of insulator 170 between end 182 and step 184. Moreover,in this example, the head 151 of Huck pin 150 is in the form of acountersink (tapered) head that is received in a correspondingcountersink opening in thin section 180 of plate 168. The use of afastener with a countersink head avoids the heads of fasteners 150shown, for example, in FIGS. 12A-12B, from extending from a side, e.g.,the bottom, of the corresponding gauge plate.

With reference to FIGS. 18A-18D, a gauge plate assembly 80H according toa further embodiment includes a single metallic core 100 surrounded byan electrically insulating material 106. In this example, theelectrically insulating material 106 can be a single or multi-layerinsulator. In an example, the surface of metallic core 100 facing awayfrom metallic plates 130, 132 can be covered by a fiberglass insulatorwhile the remaining portions, i.e., the sides and surface of metallicplate 100 facing plates 130, 132, can be covered by an electricallyinsulating epoxy, although other suitable arrangements may be utilized.Instead of the depending leg 112 shown in FIGS. 9A-9C, the gauge plateassembly 80H shown in FIGS. 18A-18D can include a portion 196 of theinsulating material 106 e.g., the electrically insulating epoxy, thatdepends from metallic core 100 and which surrounds, at least partiallyconformingly, a cylindrical structure 198, such as a PVC pipe, thatextends between the facing ends of plates 130 and 132.

FIGS. 18C and 18D show two variations of the gauge plate assembly 80Hshown in FIG. 18B. In FIG. 18C, the electrically insulating material 106is in the form of a hollow T-shaped cross-section 200 with cylindricalstructure 198 disposed in said hollow portion. In the example shown inFIG. 18C, the cylindrical structure extends between and contacts theinner surface of insulating material 106 disposed on the facing ends ofplates 130 and 132. In the example shown in FIG. 18D, the cylindricalstructure has a smaller diameter than the distance between theinsulating material 106 disposed on the facing ends of plates 130 and132. This additional spacing can account for expansion of plates 130 and132 while maintaining electrical isolation therebetween.

The gauge plate assembly 80H shown in FIGS. 18A-18D can include fourfastener holes 120 in the same pattern as the fastener holes shown inFIG. 9A. Each fastener hole 120 can extend through plate 130 or 132,metallic core 100, and insulating material 106 surrounding metallic core100. Each fastener hole 120 can be configured to receive the shaft of aHuck pin 150 which can be secured in place by a flat washer 152 and aHuck collar 154 in a manner known in the art. An optional lifting bale160 can be provided including parts 162 that can be positioned orsandwiched between the pair of washers 152 and a top surface of theelectrically insulating material 106 surrounding metallic core 100.Finally, an insulating bushing 122 can be received in the portion ofeach fastener hole 120 that extends through metallic core 100 in orderto insulate metallic core 100 from each plate 130 and 132.

With reference to FIGS. 19A-19B, a gauge plate assembly 80I according toa further embodiment is similar in most respects to the gauge plateassembly 80H shown in FIGS. 18A-18D with at least the followingexceptions. The portions 196 of the hollow electrically insulatingmaterial 106 shown in FIGS. 18A-18D can be omitted whereupon metalliccore 100 and electrically insulating material 106 can be plate-shaped,and an elongated insulating structure 202, such as an elongated PVC pipeor tube, can be positioned between the facing ends of plates 130 and132. In this example, structure 202 can be square or rectangular and canhave a solid or hollow center.

With reference to FIGS. 20A-20B, a gauge plate assembly 80J according toa further embodiment is similar in most respects to the gauge plateassembly 80H shown in FIGS. 18A-18D with at least the followingexceptions. The metallic core 100 includes its top and side surfacessurrounded by insulator 106. However, in this example, the portion ofmetallic core 100 above a gap 204 between the facing surfaces of plates130 and 132 is left uncovered by insulating material 106 and insulatingmaterial 106 covers the facing ends 206 and 208 of plates 130 and 132.

With reference to FIGS. 21A-21B, a gauge plate assembly 80K according toa further embodiment includes a T-shaped insulating plate 210 (shown incross-section in FIG. 21B) that includes a planar body 212 and adepending leg 214 that has generally the same shape as the depending leg112 shown in FIGS. 9A-9C. A metallic plate 216 is positioned on a sideof body 212 of insulating plate 210 opposite depending leg 214. In theillustrated example, metallic plate 216 is received completely withinthe perimeter of insulating plate 210, although other suitablearrangements may be utilized.

A plurality of fastener holes 218 extends through plates 130 and 132,insulating plate 210, and metallic plate 216. An insulating bushing 220can be received in each fastener hole 218, at least in the portion offastener hole 218 defined by metallic plate 216, to isolate the shaft ofthe Huck pin 222 projected through the fastener hole 218 from metallicplate 216. Each Huck pin 222 can be secured in its respective fastenerhole 218 via an insulating washer 224 received on the shaft of Huck pin222 and in contact with a surface of metallic plate 216 oppositeinsulating plate 210, a flat washer 226 disposed on a side of insulatingwasher 224 opposite metallic plate 216, and a Huck collar 228 receivedon the threaded end of the shaft of the Huck pin 222 on a side of flatwasher 226 opposite insulating washer 224. An optional lifting bale 160,including parts 162, can be provided, with each part 162 sandwichedbetween an insulating washer 224 and a flat washer 226. In theillustrated example, insulating washers 224 are square or rectangular.However, this is not to be construed in a limiting sense.

With reference to FIGS. 22A-22B, a gauge plate assembly 80L according toa further embodiment is similar in most respects to the gauge plateshown in FIGS. 21A-21B with at least the following exceptions. Insteadof the single metallic plate 216 shown in FIGS. 21A-21B, the gauge plateassembly 80L shown in FIGS. 22A-22B includes a pair of elongatedmetallic plates 230 positioned in spaced relation on opposite sides ofdepending leg 214 of insulating plate 210. As can be seen, the elongatedaxis of each plate 230 runs generally in the same direction as theelongated length of depending leg 214.

Because the pair of plates 230 are spaced from each other, theinsulating washers 224 shown in FIGS. 21A-21B can be omitted in thegauge plate assembly 80L shown in FIGS. 22A-22B.

With reference to FIGS. 23A-23B, a gauge plate assembly 80M according toa further embodiment is similar in many respects to the gauge plateassembly 80L shown in FIGS. 22A-22B with at least the followingexceptions. The thickness of the body 212 of insulator 210 is increasedto ⅝ inch versus ⅜ inch in FIGS. 22A-22B and metallic plates 230 andbushings 220 of the gauge plate assembly 80L shown in FIGS. 22A-22B areomitted in the gauge plate assembly 80M shown in FIGS. 23A-23B.

With reference to FIGS. 24A-24B, a gauge plate assembly 80N according toa further embodiment is similar in most respects to the gauge plateshown in FIGS. 22A-22B with at least the following exceptions. Themetallic plates 230 shown in FIGS. 22A-22B are replaced in the gaugeplate assembly 80N shown in FIGS. 24A-24B with metallic washers 232 andwith one metallic washer 232 for each Huck pin 222. As can be seen,metallic washers 232 are spaced from each other and are electricallyisolated from each other by insulating plate 210. Because of thiselectrical isolation, insulating bushings 220 shown, for example, inFIGS. 21A-21B, are not required.

Referring to FIG. 29, the insulating plate 210 of the gauge plateassemblies 80K-80N shown in FIGS. 21A-24B may be formed utilizing apultrusion process. In particular, the insulating plate 210 may beintegrally formed from a fiber-reinforced polymer using the pultrusionprocess. According to one aspect or example, a method 270 formanufacturing the insulating plate 210 includes impregnating a fiberreinforcement with resin 272; pulling the fiber reinforcementimpregnated with the resin through a forming die 274 to form a profileof the insulating plate 210; heating the profile to cure the resin 276;and cutting the profile to a predetermined length 278. The fiberreinforcement may be fiberglass, such as E-class fiberglass or S-classfiberglass, although other suitable reinforcing fibers and combinationsmay be utilized. The resin may be polyester, vinyl ester, polyurethane,or epoxy, although other suitable resins and combinations may beutilized. During the resin impregnation step, a catalyst may be mixedwith the resin to facilitate the curing of the resin. Other suitablepigments and fillers may also be utilized in connection with the resinand reinforcing fiber.

The reinforcing fiber may be provided from a reinforcement supply 280,which may include rovings of fiber or rolls of fiber mat. Before and/orafter the reinforcing fiber is impregnated with the resin, thereinforcing fiber may undergo a preforming process 282 to preform thereinforcing fiber to prepare the reinforcing fiber for the formingprocess. After the fiber reinforcement is impregnated with the resin,the method may include applying a surfacing veil 284 to the fiberreinforcement. The forming and heating step 274,276 may occursimultaneously with a heat source being provided as the fiberreinforcement and resin pass through the forming die, although othersuitable arrangements may be utilized. As noted above, the method 270includes pulling 286 the fiber reinforcement through a forming die,which may be accomplished using any suitable pulling system, such as acaterpillar-style system or reciprocating system. The cutting step 278may be accomplished via a cut-off saw, although other suitablearrangements may be utilized.

Although the method 270 is described in connection with the insulatingplate 210, the method 270 may be utilized in connection with othercomponents and elements of the present application.

With reference to FIGS. 25A-25B, a gauge plate assembly 80O according toa further embodiment is similar in many respects to the gauge plateassembly 80M shown in FIGS. 23A-23B with at least the followingexceptions. In the gauge plate assembly 80O shown in FIGS. 25A-25B, thethickness of body 212 is increased to ¾ inch from ⅝ inch shown in FIGS.23A-23B. In addition, insulating plate 210 is formed with a core 234 ofa glass fabric impregnated with epoxy resin, e.g., the well-known G10laminate, encased in an insulating material 236, e.g., polyethylene. Theinsulating material 236 encasing core 234 also forms depending leg 214.Because core 234 and insulating material 236 of insulating plate 210 areboth formed of insulating material, no bushings are required to insulatethe shafts of Huck pins 222 from insulating plate 210 or plates 130,132. In the illustrated example, core 234 has a thickness of ⅜ inch,although other suitable thicknesses may be utilized.

With reference to FIGS. 26A-26B, a gauge plate assembly 80P according toa further embodiment is similar in most respects to the gauge plateassembly 80M shown in FIGS. 23A-23B with at least the followingexceptions. The thickness of body 212 of insulating plate 210 is set at⅜ inch versus ⅝ inch shown in FIGS. 23A-23B. In addition, positionedbetween insulating plate 210 and washers 226 is an insulating plate 238formed of a glass fabric impregnated with epoxy resin. In an example,insulating plate 238 can be formed from commercially available material,such as the well-known G10 laminate.

As shown in FIGS. 26A and 26B, insulating plate 238 covers the entireupward facing surface of body 212 of insulating plate 210 and extendsbetween all of the shafts of Huck pins 222. Because of the insulatingproperties of insulating plate 210 and insulating plate 238, no bushingsare required to isolate the shafts of Huck pins 222 from insulatingplate 210 and/or insulating plate 238, in order to maintain Huck pins222 electrically isolated from each other and electrically isolated fromplates or members 130, 132.

With reference to FIGS. 27A-27C, a gauge plate assembly 80Q according toa further embodiment is similar in most respects to the gauge plateinsulator 70 shown in FIGS. 9A-9C with at least the followingexceptions. Each metallic core 100 includes squared first and secondends 114, 116, versus radiused or rounded ends 114 and 116 shown in FIG.9A. Moreover, the body 110 of insulating material 106 encasing eachmetallic plate 100 is a rectangular cube-like structure 240. Eachrectangular cube-like structure 240 rises a distance 242 above a firstlevel 244 of the surface of insulating material 106. In the exampleshown in FIGS. 27A-27C, the total distance between the bottom surface246 of body 110 of insulating plate 106 and a top surface 248 of eachrectangular cube-like structure 240 is ¾ inch and distance 242 betweenfirst level 244 and the top surface 248 of each rectangular cube-likestructure 240 is ⅜ inch, although other suitable arrangements may beutilized.

With reference to FIGS. 28A-28C, a gauge plate insulator 90 according toa further embodiment is similar in most respects to the gauge plateinsulator 70 shown in FIGS. 9A-9C with at least the followingexceptions. The plateaus 126 of the gauge plate insulator 70 shown inFIGS. 9A-9C are omitted in the gauge plate insulator 90 shown in FIGS.28A-28C in favor of the surface 127 being planar. The optional expansionslots 124 are also omitted in the example gauge plate shown in FIGS.28A-28C.

Moreover, the gauge plate insulator 90 of FIGS. 28A-28C includes abridge 250 formed of electrically insulating material 106 between metalplates 100. In an example, this bridge 250 is in vertical alignment withdepending leg 112, although other suitable arrangements may be utilized.As can be seen, bridge 250 is formed by the omission of electricallyinsulating material 106 in spaces 252 on either side of bridge 250 anddepending leg 112. As shown best in FIG. 28A, the gauge plate insulator90 has an H-shape wherein the legs of the “H” are formed by the pair ofsteel cores 100 encased by insulating material 106 and the bar thatextends between the legs defines bridge 250 and is formed solely ofinsulating material 106.

In the example shown in FIGS. 28A-28C, the opposite sides of bridge 250are curved or arched 254 away from depending leg 112, although othersuitable arrangements may be utilized. The portions of insulatingmaterial 106 around each steel core 100 can also be curved around theircorners to avoid sharp edges.

The foregoing examples have been described with reference to theaccompanying figures. Modifications and alterations will occur to othersupon reading and understanding the foregoing examples which are providedfor the purpose of illustration and are not to be construed in alimiting sense. For example, while the use of Huck pins and Huck collarsis disclosed, the use of any other suitable and/or desirable fastenerarrangement in replacement of a Huck pin/Huck collar combination isenvisioned. Accordingly, the foregoing examples are not to be construedas limiting the disclosure

The invention claimed is:
 1. A gauge plate insulator comprising: a bodyhaving a first side and a second side positioned opposite the second,the first side of the body defining a planar surface, the body defininga first opening and a second opening; and a leg extending from thesecond side of the body and configured to be positioned between firstand second gauge plate members, the leg positioned between the first andsecond openings of the body, wherein the body and leg are formedintegrally from a fiber-reinforced polymer.
 2. The gauge plate insulatorof claim 1, wherein the fiber-reinforced polymer comprises at least oneof fiberglass-reinforced polyester, fiberglass-reinforced vinyl ester,fiberglass-reinforced polyurethane, and fiberglass-reinforced epoxy. 3.The gauge plate insulator of claim 1, wherein fiber-reinforced polymercomprises at least one of E-class fiberglass and S-class fiberglass. 4.The gauge plate insulator of claim 1, further comprising a firstfastener configured to be received by the first opening and to securethe body to a first gauge plate member and a second fastener configuredto be received by the second opening and to secure the body to a secondgauge plate member.
 5. The gauge plate insulator of claim 4, wherein thefirst and second fasteners each comprise a huck collar and huck pin. 6.The gauge plate insulator of claim 4, further comprising a first washerconfigured to be positioned between a portion of the first fastener andthe body and a second washer configured to be positioned between aportion of the second fastener and the body.
 7. The gauge plateinsulator of claim 6, wherein the first and second washers each comprisea hardened flat washer.
 8. The gauge plate insulator of claim 4, furthercomprising a metallic plate, first and second insulating washers, andfirst and second insulating bushings, the metallic plate is configuredto be received by the first side of the body and defines first andsecond openings corresponding to the first and second openings of thebody, the first insulating washer configured to be positioned between aportion of the first fastener and the metallic plate, the secondinsulating washer configured to be positioned between a portion of thesecond fastener and the metallic plate, the first insulated bushingreceived within the first opening and configured to receive the firstfastener and the second insulated bushing received within the secondopening and configured to receive the second fastener.
 9. The gaugeplate insulator of claim 1, wherein the first opening comprises a pairof spaced-apart openings and the second opening comprises a pair ofspaced-apart openings, the gauge plate insulator further comprising afirst elongate metallic plate extending between the pair of spaced-apartopenings of the first opening, a second elongate metallic plateextending between the pair of spaced-apart openings of the secondopening, the first and second elongate metallic plates positionedparallel to the leg.
 10. The gauge plate insulator of claim 1, furthercomprising an insulating plate positioned in the first side of the body.11. The gauge plate insulator of claim 10, wherein the insulating platecomprises a glass fabric impregnated with epoxy resin.
 12. A method ofmanufacturing a gauge plate insulator comprising a body having a firstside and a second side positioned opposite the second, and a legextending from the second side of the body and configured to bepositioned between first and second gauge plate members, the methodcomprising: impregnating a fiber reinforcement with resin; pulling thefiber reinforcement impregnated with the resin through a forming die toform a profile of the body and leg of the gauge plate insulator; heatingthe profile to cure the resin; and cutting the profile to apredetermined length.
 13. A gauge plate insulator comprising: a pair oflaterally spaced, elongated, planar metallic cores, each of thelaterally spaced, elongated, planar metallic cores extend in a firstdirection; and an electrically insulating material encasing the pair oflaterally spaced, elongated, planar metallic cores, the electricallyinsulating material defining an insulating member that includes aT-shaped cross section defined by a body of the electrically insulatingmaterial and a leg of the electrically insulating material that dependsfrom the body, the depending leg having an elongated dimension thatextends in a second direction laterally to the first direction.
 14. Thegauge plate insulator of claim 13, wherein: each elongated, planarmetallic core has a first end and a second end; and the elongateddimension of the depending leg extends between the first and second endsof each elongated, planar metallic core.
 15. The gauge plate insulatorof claim 14, further including a plurality of fastener holes, whereineach fastener hole extends through the body of the electricallyinsulating member and one of the metallic cores.
 16. The gauge plateinsulator of claim 15, wherein each metallic core is comprised of two ofthe plurality of fastener holes, wherein one of the two fastener holesof the metallic core is positioned between the elongated dimension ofthe depending leg and the first end of the metallic core, and the otherof the two fastener holes of the metallic core is positioned between theelongated dimension of the depending leg and the second end of themetallic core.
 17. The gauge plate insulator of claim 15, furthercomprising an insulating bushing in each fastener hole.
 18. The gaugeplate insulator of claim 13, wherein the body of the electricallyinsulating material defines a pair of plateaus that extend above asurface of the body that faces away from the depending leg, wherein eachplateau encases a surface of one of the metallic cores that faces awayfrom the depending leg and at least a part of a side of the metalliccore.
 19. The gauge plate insulator of claim 13, wherein a top of theelectrically insulating member forms an H-shape.
 20. A gauge plateinsulator comprising: an L-shaped insulating member having a baseconfigured to be positioned between first and second gauge plate membersand a leg extending from the base; a metallic backing plate having afirst part configured to engage a first gauge plate member, a secondpart configured to engage the leg of the L-shaped insulating member, anda third part extending between the first part and the second part of themetallic backing plate and configured to engage a portion of the base ofthe L-shaped insulating member; a first fastener configured to bereceived by a first opening defined by the first part of the metallicbacking plate to secure the metallic backing plate to a first gaugeplate member and a second fastener configured to be received by a secondopening defined by the second part of the metallic backing plate and anopening defined by the leg of the L-shaped insulating member; and aninsulation plate configured to be positioned between a portion of thesecond fastener and the second part of the metallic backing plate.
 21. Agauge plate assembly comprising: a first gauge plate member having athick section and a thin section adjacent an end of the first gaugeplate member; a second gauge plate member having a thick section and athin section adjacent an end of the second gauge plate member, a portionof the thin section of the first gauge plate member overlapping aportion of the thin section of the second gauge plate member; aninsulating member positioned between the first and second gauge platemembers; at least one fastener extending through an opening extendingthrough the thin sections of the first and second gauge plate membersand the insulating member; and an insulation plate positioned between aportion of the at least one fastener and the thin section of the secondgauge plate member.
 22. The gauge plate assembly of claim 21, whereinthe insulating member is thicker adjacent to a transition between thethick section and the thin section of the first gauge plate member, andwherein the insulating member is thicker adjacent to a transitionbetween the thick section and the thin section of the second gauge platemember.
 23. The gauge plate assembly of claim 21, wherein the insulationplate is formed integrally with the insulating member.